Step 5: Add a Face Shield

Step 6: Testing

I have used my All-Weather Helmet for two winters, and I'm working on the third! I have ridden in temperatures down to -20 Celsius, and hit speeds of ...

I ride my bike all year round, and since I live in Canada that means I have to bundle up quite a bit in the winter! When temperatures dip below 5 Celsius or so, I put my "summer" helmet back on the shelf and reach for my custom modified all-weather helmet. It's so effective that despite my mostly bald head I don't need to wear a hat underneath, even at temperatures down to -20C at speeds in excess of 40 km/h (tested and confirmed!)

The All-Weather Helmet is also completely waterproof, so it's great to have when it's raining, sleeting, or snowing.

Virtually any helmet can be modified into an all-weather helmet, the only requirement is that the plastic decorative shell can be removed.

PARTS:

One bike helmet in your size. Make sure the plastic part comes off.
About one square yard (or one square meter) of nylon fabric
Contact cement or some other glue with a long open time, that won't melt foam
Electrician's tape
A plastic face shield (optional)

Step 1: Remove the Plastic Shell

The first step is to remove the plastic decorative shell that is stuck to the foam of the helmet. Chances are it will be taped around the edges, and maybe glued in a few spots here and there underneath. If your helmet is more securely attached (like my Giro "summer" helmet) then this may not work so well.

If your helmet has a visor, pop it off and set it aside.

Start by cutting the tape around the perimeter, or just peeling it off. Lift the plastic cover at one end, and feel for the first spots of glue. Gently break the glue connection, being careful not to dent the plastic or pull pieces of foam off the actual helmet. Use a metal shim, such as a ruler, to make this easier. Do this for all the glue spots, until the plastic cover comes loose.

I took a slightly different approach. I found a visor made for motorcycle or scooter helmets (?) on ebay. I secured it with commercial zipties, then secured my EVT SafeZone mirror on top of that. A commuter's dream helmet. Rock solid mirror, let's me keep an eye on overtaking traffic, no wobble or shake. Visor or shield can pivot up and out of the way when not needed. Where I commute it is mostly swampland, so it is hot and humid, with lots of bugs keen on lodging themselves in your eyes. Also it rains, and the shield keeps rain from building up on my glasses (a real problem before).

I have to weigh in on this instructable because taking off the plastic shell and putting nylon in between compromises the integrity of the helmet. I've been in a number of accidents where my helmet was destroyed and I can tell you that helmets are only good for one use and should never be compromised. when I ride in the winter, I use the louis garneau time trial helmet, its the one that the visor you use is designed for, it has less air holes than a standard helmet and covers the ears, I also wear a thin thermal hoodie underneath the helmet.

The key here is that the outer shell on this particular helmet is really on there for looks. It's held on with tape and a few dabs of glue here and there. On other helmets, like those made by Giro, the plastic shell is indeed part of the structure, and should not be removed in this way.

For the most part, a generous application of bike lube, WD-40, or marine-grade grease. It also helps that many of the components (including the frame) and fasteners are made of aluminum and stainless steel.

I live in Tennessee where it doesn't snow much, but right now it is under 20 degrees Fahrenheit. I ride my bike year-round and this helmet seems like a good idea for the winter time. But now I am anticipating spring so I might consider something like this for next winter...